Bag packaging method and assembly for a bag filling station

ABSTRACT

A packaging method and assembly includes a bag loading assembly operable to load single sized bags into a loading station at a plurality of distances and a cutter assembly operable to cut the single sized bag to a desired size. A bag manipulating assembly operable to open the bag to allow a package to be inserted into the bag and to seal the bag after the package has been inserted into the bag. The packaging method and assembly also preferably includes a tail remover that removes the cut tail of the bag from the packaging assembly.

FIELD OF THE INVENTION

[0001] The invention relates to devices for opening, filling, and sealing plastic bags and other packaging. More particularly, the invention relates to automated devices that can produce an air-tight seal when packaging bulky products.

BACKGROUND OF THE INVENTION

[0002] Bag opening and filling devices have been developed for a wide variety of applications. Typically, these devices include one or more mechanisms for selecting a single bag from a stack of flattened, usually folded bags, and holding the selected bag open for filling. Prior-art devices commonly include a wicket that holds a stack of bags to be filled. Bags are torn from the wicket and opened prior to filling. Once the bag is opened, a pusher mechanism loads the product into the bag and a sealing mechanism seals the bag after the product has been loaded.

[0003] In modern packaging applications many different types of products are loaded into bags. It is difficult to obtain an air-tight or hermetic seal using available automated sealing equipment when packaging bulky products, such as diapers, sanitary napkins, paper napkins, and similar products. Fortunately, it is unnecessary to package these types of products in air-tight bags. However, there are applications that require hermetic sealing of the bag.

[0004] Packaging medical supplies is one such application. Hermetic sealing is required to ensure that the medical supplies are not contaminated after they are packaged and sealed in the bags. Attempts to automate the packaging and sealing of bulky medical supplies have been unsuccessful due to the problems associated with placing a bulky object in a flat bag and then attempting to bring the open edges of the bag together for sealing. The open edges wrinkle, which prevents the formation of a proper seal along the entire length of the bag opening. Consequently, bulky medical supplies are packaged and sealed by hand to ensure that a hermetic seal is produced. Manual packaging and sealing has several deficiencies. It is cumbersome, time-consuming, and vulnerable to human error.

SUMMARY OF THE INVENTION

[0005] Thus, there is a need for an automated packaging device that can be used to package medical supplies and other products in bags and to hermetically seal the bags. In addition, it would be beneficial if such a machine could monitor the quality of the seal. Further still, there is a need for a device where a relatively large number of bags can be loaded or otherwise provided to the packaging device so that product can be packaged at a relatively high rate without the need for replenishing the supply of bags at a similarly high rate.

[0006] In one embodiment, the invention provides an automated bag filling station or packaging device capable of rapidly packaging medical supplies and other bulky products in bags and sealing the bags in an air-tight manner. The packaging device includes a welding assembly for a bag filling device. The welding assembly includes an upper jaw movable in a substantially vertical plane and a lower jaw movable in the same substantially vertical plane as the upper jaw and supported on the frame via two support members. The welding assembly also includes a pressure sensor coupled to the jaws for measuring a welding pressure between the jaws. A processor coupled to the pressure sensor receives a signal from the pressure sensor to determine the conditions under which the weld was created.

[0007] In one aspect of the invention, the pressure sensor is mounted on one of the support members. In another aspect of the invention, the pressure sensor is mounted in a recess in one of the upper and the lower jaws.

[0008] In yet another aspect of the invention, the welding assembly includes a temperature sensor for measuring the temperature between the welding jaws during sealing. The welding assembly also includes a timer for determining the length of time in which the welding jaws seal the bag.

[0009] In another embodiment, the invention provides a method of sealing a bag. The method includes positioning a bag between upper and lower jaws and moving the jaws together in a substantially vertical plane to seal the bag. The method further includes sensing a pressure between the jaws when the jaws are together and sending pressure measurements to a processor. The processor then determines the quality of the seal by analyzing whether the pressure measurements fall within a predetermined set of allowable limits.

[0010] In one aspect of the invention, sensing the pressure includes positioning a pressure sensor on a support member coupled to one of the upper and the lower jaws. Additionally, a second pressure sensor can be positioned on a second support member. Preferably, the support members are substantially vertical when the jaws are together to obtain accurate pressure measurements. In another aspect of the invention, sensing the pressure between the jaws includes positioning a pressure sensor in a recess in one of the upper and the lower jaws.

[0011] In yet another aspect of the invention, the method further includes sensing a temperature between the jaws when the jaws are together and sending temperature measurements to the processor to determine the quality of the seal by analyzing whether the temperature measurements fall within a predetermined set of allowable limits.

[0012] In a further embodiment, the invention provides an automated packaging device for packaging objects at high speeds. The device includes a bag loading assembly that can be manipulated to feed single sized bags into a loading station at a plurality of distances. The device also includes a cutter assembly that cuts the bags to a desired size, prior to filling the bag. The device also includes a bag manipulating assembly that opens the bags to allow a package to be inserted into the bag, and that seals the bag after the package has been inserted.

[0013] Other features and advantages of the invention will become apparent to those skilled in the art upon review of the following detailed description, claims, and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014]FIG. 1 is a side view of an automated packaging device embodying the invention.

[0015]FIGS. 1a and 1 b are top views of the package loading assembly in various operating states.

[0016]FIG. 2 is an enlarged side view showing one of the support members of FIG. 1 in the package sealing position.

[0017]FIG. 3 is an enlarged side view showing the bag loading assembly of the device of FIG. 1.

[0018] FIGS. 4-6 are side views of the conveyor assembly portion of the bag loading assembly of FIG. 3 shown in various operational states.

[0019]FIG. 7 is a partially cut away view of the conveyor assembly taken along line 7-7 in FIG. 4.

[0020]FIG. 8 is a front view showing a loading station, a bag manipulating assembly, and a bag welding assembly of the device of FIG. 1.

[0021]FIG. 9 is an enlarged front view of the loading station and the bag manipulating assembly shown with a bag opened for receiving a package.

[0022]FIG. 10 is a perspective view of the loading station, the bag manipulating assembly, and a portion of a bag loading assembly loading a package into the opened bag.

[0023]FIG. 11 is an alternative gripper arrangement that can be used with the bag manipulating assembly.

[0024]FIG. 12 is a sectional view of the welding jaws showing an alternative pressure sensor configuration.

[0025] FIGS. 13-20 sequentially illustrate, in cross-section from the side, the opening, closing, and sealing of the bag.

[0026] FIGS. 21-28 sequentially illustrate, from the front, the opening, closing, and sealing of the bag.

[0027]FIG. 29 is a sealed bag containing a package.

[0028] FIGS. 30-32 illustrate an alternative spreader plate arrangement for the bag manipulating assembly.

[0029]FIG. 33 is a front view of an alternate embodiment of a bag filling station.

[0030]FIG. 34 is a side view of the bag filling station illustrated in FIG. 33.

[0031]FIG. 35 is a side view of a portion of the bag filling station illustrated in FIG. 33 in a first position.

[0032]FIG. 36 is a side view of a portion of the bag filling station illustrated in FIG. 33 in a second position.

[0033]FIG. 37 is a side view of a portion of the bag filling station illustrated in FIG. 33 in a third position.

[0034]FIG. 38 is a side view of a portion of the bag filling station illustrated in FIG. 33 in a forth position.

[0035]FIG. 39 is a side view of a portion of the bag filling station illustrated in FIG. 33 in a fifth position.

[0036]FIG. 40 is a side view of a portion of the bag filling station illustrated in FIG. 33 in a sixth position.

[0037]FIG. 41 is a side view of a portion of the bag filling station illustrated in FIG. 33 in a seventh position.

[0038]FIG. 42 is a side view of a portion of the bag filling station illustrated in FIG. 33 in an eighth position.

[0039]FIG. 43 is a side view of a portion of the bag filling station illustrated in FIG. 33 with a transfer plate and a gripper plate shown in a plurality of positions.

[0040] Before the invention is explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of multiple embodiments and of being practiced or being carried out in various ways. Also, it is understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.

DETAILED DESCRIPTION

[0041] A bag filling station 50 of one embodiment is shown in FIG. 1. The bag filling station 50 includes a frame 54 (only partially shown) that supports the bag filling station 50. The frame 54 can also support protective walls (not shown) positioned around the bag filling station 50, as is commonly understood.

[0042] The bag filling station 50 includes a loading station 58 positioned within the frame 54, a package loading assembly 62 coupled to the frame 54 adjacent the loading station 58, a bag loading assembly 66 coupled to the frame 54 adjacent the loading station 58, a bag manipulating assembly 70 coupled to the frame 54 adjacent the loading station 58, and a bag welding assembly 74 (see FIG. 8) coupled to the frame 54 adjacent the loading station 58. For purposes of description only, the bag filling station 50 can be defined in terms of a front 78, adjacent the package loading assembly 62, a rear 82 adjacent the bag loading assembly 66, a right side 86, and a left side 90 (see FIG. 8). A longitudinal axis 94 (see FIGS. 1, 1a, 1 b, 9, and 10) extends from the front 78 to the rear 82 through the loading station 58.

[0043] As seen in FIGS. 1, 1a, 1 b, and 10, the package loading assembly 62 includes a package conveyor assembly 98 capable of transporting packages 102 to the loading station 58. The package conveyor assembly 98 includes a conveyor table 106 supported by support legs 110 (see FIG. 1). The conveyor table 106 includes an endless conveyor belt 114 (see FIG. 10) driven by a drive device 118 (see FIG. 1). A suitable conveyor table 106 is available from Dorner Manufacturing of Hartland, Wis. The drive device 118 can be any suitable device capable of moving the conveyor belt 114, such as an electric motor.

[0044] The package conveyor assembly 98 also includes a pair of pusher arm assemblies 122 movably coupled to the conveyor table 106. The pusher arm assemblies 122 are substantially identical, and only one will be described. As seen in FIG. 1, the pusher arm assembly 122 includes a slide 126 mounted on a support member 130 for reciprocating linear movement in the direction of the longitudinal axis 94. The linear movement of the pusher arm assembly 122 is driven by any linear actuator (not shown) such as a hydraulic or pneumatic actuator, a rack and pinion system, and the like, or can be driven by the drive device 118.

[0045] The pusher arm assembly 122 also includes a pusher arm 134 having a pushing end 138 for pushing a package 102 into the loading station 58. As best seen in FIG. 1a, the pusher arm 134 is movable between a retracted position P_(R) (shown in solid lines in FIG. 1a), where a package 102 can be advanced on the conveyor table 106 between the two pusher arms 134 toward the loading station 58, and an extended position P_(E) (shown in phantom lines in FIG. 1a), where the two pusher arms 134 overlie the conveyor table 106. As shown in FIG. 1b, when in the extended position, the pusher arms move linearly from the position P₁ (shown in solid lines in FIG. 1b), to the position P₂ (shown in phantom lines in FIG. 1b) so that the pushing ends 138 can push the package 102 into the loading station 58.

[0046] Any suitable method of causing the movement of the pusher arms 134 between the retracted and extended positions can be used, including hydraulic or pneumatic actuators, rack and pinion systems, and the like. While the package conveyor assembly 98 preferably includes two pusher arm assemblies 122, it is understood that only one pusher arm assembly 122 could be used. Pusher arm assemblies having other configurations are also contemplated, including those shown in U.S. Pat. No. 5,799,465 incorporated by reference herein.

[0047] The package conveyor assembly 98 also preferably includes a sensor 142 (see FIG. 1) that senses the presence of a package 102 on the conveyor table 106 when the package 102 is adjacent the loading station 58. The sensor 142, which can be in the form of an optical sensor, a limit switch, or the like, communicates with the pusher arm assemblies 122 so that the pusher arm assemblies 122 are activated to push the package 102 when the package 102 is in position adjacent the loading station 58.

[0048] The package conveyor assembly 98 can also include guide rails 144 (see FIGS. 1a and 1 b) on either side of the conveyor table 106 extending substantially parallel to the longitudinal axis 94 to help guide the package 102. The guide rails 144 can be adjustable to accommodate packages 102 of varying heights and widths.

[0049] As seen in FIGS. 1 and 3-7, the bag loading assembly 66 includes a bag feeder or bag conveyor assembly 146 capable of transporting a bag 150 to the loading station 58 for receiving a package 102. The bags have an open end for receiving the package 102. The bag conveyor assembly 146 includes a conveyor assembly 154 supported by support legs 158. As best seen in FIGS. 3-7, the conveyor assembly 154 includes a conveyor table 160 comprised of a body portion 162, a drive roller 166, a follower roller 170, a pair of tensioner rollers 174, an endless conveyor belt 178 encircling portions of the body portion 162 and the rollers 166, 170, and 174, and side supports 180 (only one is shown in FIG. 3).

[0050] The body portion 162 includes an upper cavity 182 and a lower cavity 186 separated by a wall 190. The wall 190 separates the cavities 182, 186 such that there is substantially no fluid communication between the cavities 182, 186. Upper and lower inlet ports 194 and 198, respectively (see FIG. 3), provide fluid communication to the cavities 182, 186 as will be described below. The body portion 162 further includes a top surface 202 having elongated apertures 206 communicating between the top surface 202 and the upper cavity 182. The body portion 162 also includes a bottom surface 210 having elongated apertures 214 that are substantially identical to the apertures 206 and that communicate between the bottom surface 210 and the lower cavity 186. The body portion 162 has an overall width W (see FIG. 7).

[0051] Vacuum from a vacuum generator 218 (see FIG. 1) is applied to the body portion 162 through separate supply hoses 222 and 223. The upper supply hose 222 provides vacuum to the upper cavity 182 through the upper inlet port 194. The lower supply hose 223 provides vacuum to the lower cavity 186 through the lower inlet port 198. Of course, two separate vacuum generators could be used.

[0052] The elongated apertures 206, 214 supply vacuum to the respective top and bottom surfaces 202, 210 over a working width W′ (see FIG. 7). The working width W′ of vacuum at the top and bottom surfaces 202, 210 is adjustable to accommodate the width of the bags 150 being used. In one embodiment, as shown in FIG. 7, a working width adjustment mechanism 226 is used to selectively block and unblock all or portions of some of the apertures 206, 214. To accomplish this, a pair of slide plates 230 (only the top slide plate is shown in FIG. 7) is moved to block and unblock the apertures, 206, 214. The slide plates 230 can be actuated manually or automatically.

[0053] The drive roller 166 is spaced from one end of the body portion 162, preferably in the rearward direction, and is supported for rotation between the side supports 180. A drive device 234 drives the drive roller 166. In one embodiment, the drive device 234 is an electric motor, and more preferably an electric motor that is programmed to actuate the drive roller 166 through a predetermined number of revolutions in either direction as will be described below. Alternatively, a standard electric motor could be used in conjunction with a sensing device (not shown) such as an optical sensor, a limit switch, or the like.

[0054] The follower roller 170 is spaced from the end of the body portion 162 opposite the drive roller 166, and is also supported for rotation between the side supports 180. The follower roller 170 preferably includes a cavity 238 that communicates with apertures 242 formed in the surface of the follower roller 170. A vacuum is applied to the follower roller 170 as shown schematically in FIG. 7. The vacuum generator 218 or a separate vacuum generator (not shown) is used to supply vacuum to the follower roller 170. It should be understood, however, that the follower roller 170 need not be configured to provide vacuum.

[0055] The endless conveyor belt 178 encircles the rollers 166, 170 such that there is always a portion of the conveyor belt 178 engaging both the top surface 202 and the bottom surface 210. The tensioner rollers 174 are supported for rotation between the side supports 180 as shown in FIG. 3, and at least one of the tensioner rollers 174 is movable to adjust the tension in the conveyor belt 178 as is understood. Of course other arrangements can be used to adjust the tension of the conveyor belt 178.

[0056] As seen in FIG. 7, the conveyor belt 178 includes a plurality of transverse apertures 246 that provide communication between the outer surface of the conveyor belt 178 and the respective top and bottom surfaces 202, 210 so that the vacuum supplied from the vacuum generator 218 to the body portion 162 can communicate with the outer surface of the conveyor belt 178. In the illustrated embodiment, each transverse aperture 246 communicates with two apertures 206 when adjacent the top surface 202 and two apertures 214 when adjacent the bottom surface 210. The transverse apertures 246 also communicate with the apertures 242 in the follower roller 170 so that a vacuum is also applied to the outer surface of the conveyor belt 178 as the conveyor belt 178 passes over the follower roller 170.

[0057] Although it is preferable to use vacuum, the conveyor table 160 need not be configured to supply vacuum to the conveyor belt 178. Rather, the conveyor table 160 could use other suitable techniques, such as static attraction, to engage and manipulate the bags 150 in the manner discussed below.

[0058] The conveyor table 160 is pivotable about the axis of rotation of the drive roller 166 between a first, substantially horizontal position P_(H) (as shown in solid lines in FIGS. 1 and 3), and a second, inclined position P_(I) (as shown in phantom lines in FIGS. 1 and 3). The purpose of this movement will be described below. A drive device 250 (see FIG. 1) is connected via linkage members 254 to one or both of the side supports 180 adjacent the follower roller 170 as shown. Activation of the drive device 250 moves the linkage members 254 to move the conveyor table 160 between the first and second positions P_(H), P_(I). Of course, other methods of moving the conveyor table 160 between the first and second positions, such as the use of actuators, rack and pinion systems, and the like, are also contemplated.

[0059] As best seen in FIGS. 1 and 3, the bag conveyor assembly 146 also includes a bag holder or cartridge tray assembly 258 underneath the conveyor table 160 for holding a stack of bags 150. A bag tray 262 is supported by the support legs 158 and receives a stack of bags 150 which are positioned between guide walls 266 (only two are shown in FIGS. 1 and 3). To facilitate replacing the stack of bags 150 in the bag tray 262, the bag tray 262 is preferably mounted on rollers 270 (see FIG. 3) and can be rolled out from underneath the conveyor table 160.

[0060] As best seen in FIG. 3, a lifting plate 274 inside the bag tray 262 is connected to a lifting mechanism 278 that is fixed to one of the support legs 158. The lifting mechanism can be an actuator, a rack and pinion system, or the like. As will be described below, the lifting mechanism 278 is actuated to move the lifting plate 274 to raise or lower the stack of bags 150 with respect to the bottom of the bag tray 262.

[0061] The conveyor assembly 154 can also include a take-off conveyor 282 (see FIGS. 3-7) for receiving filled bags 150 as they exit the conveyor table 160. The take-off conveyor 282 acts as a bridge between the conveyor table 160 and a permanent conveyor (not shown) that transports the filled bags 150 to an off-loading point. Of course, the take-off conveyor 282 can be eliminated if the permanent conveyor is arranged adjacent the drive roller 166 of the conveyor table 160.

[0062] The loading station 58 is positioned between the package loading assembly 62 and the bag loading assembly 66 and is best seen in FIGS. 1 and 8-10. The frame 54 includes a substantially rectangular support section 286 (see FIGS. 1 and 8) which substantially surrounds the loading station 58 and which supports the bag manipulating assembly 70 and the bag welding assembly 74. Upper and lower transverse shafts 290 and 294, respectively, are supported for rotation by the support section 286 and are coupled together via linkages 298. A drive device 302 (see FIG. 8) is coupled to the lower shaft 294 and selectively rotates the lower shaft 294 in either direction. When the lower shaft 294 is rotated, the linkages 298 cause rotation of the upper shaft 290.

[0063] A pair of upper support members or struts 306 are mounted to the upper shaft 290 and connect the upper shaft 290 to an upper jaw support member 310 (see FIG. 8). The upper jaw support member 310 is movably supported on substantially vertical guide rails 314 within the frame support section 286. Rotation of the upper shaft 290 causes vertical movement of the upper jaw support member 310, as will be described below.

[0064] Likewise, a pair of lower support members or struts 318 are mounted on the lower shaft 294 and connect the lower shaft 294 to a lower jaw support member 322. The lower jaw support member 322 is movably supported on the guide rails 314. Rotation of the lower shaft 294 causes vertical movement of the lower jaw support member 322, as will be described below. Each of the lower struts 318 has mounted thereon a pressure measurement device or sensor 324. The pressure sensor 324 is preferably a load cell. For reasons to be explained in more detail below, the lower struts 318 are sized so that as the lower jaw support member 322 reaches its uppermost vertical limit, the struts 318 are oriented substantially vertically as shown in FIG. 2. If the range of motion of the lower jaw support member 322 is varied for different applications, the struts 318 can be adjusted so that the struts 318 will always be substantially vertical when the lower jaw support member 322 reaches the uppermost vertical limit.

[0065] The upper and lower jaw support members 310, 322 support portions of the bag manipulating assembly 70 and the bag welding assembly 74. As best seen in FIG. 9, the lower jaw support member 322 supports a lower welding jaw 326, which will be described in more detail below. A plurality of suction cup assemblies 330 are mounted in spaced relation on a front face of the lower welding jaw 326. Each suction cup assembly 330 is connected to a vacuum supply and can selectively apply suction via a suction cup 334. As will be described below, the suction cup assemblies 330 are used to engage an open end of the bag 150.

[0066] A pair of rotary actuators 338 are also mounted on the lower jaw support member 322. Each rotary actuator includes a pin 342 that can be both rotated and translated with respect to the housing of the rotary actuator 338, as is understood. A spreader plate 346 is mounted on the pin 342 of each rotary actuator 338. The purpose of the spreader plate 346 will be described below. Together, the suction cup assemblies 330, the rotary actuators 338, and the spreader plates 346 define a lower bag spreader assembly 348.

[0067] The upper jaw support member 310 supports an upper welding jaw 350 and a substantially identical upper bag spreader assembly 352 in opposing relation to the lower bag spreader assembly 348. The upper bag spreader assembly 352 includes suction cup assemblies 354 having suction cups 358, and a pair of rotary actuators 362. Each rotary actuator 362 has a pin 366 and a spreader plate 370 mounted on the pin 366.

[0068] Additionally, the upper jaw support member 310 includes a pair of cam members 374 adjustably mounted to mounting plates 378. The cam members 374 are substantially identical and only one will be described. Each cam member 374 is fastened to one mounting plate 378 via upper and lower fasteners 382 and 383. The upper fastener 382 is received in a slot 386 in the cam member 374 such that the cam member 374 is pivotally adjustable about the lower fastener 383. The cam member 374 further includes a cam surface 390 corresponding to an edge of the cam member 374. Adjustment of the cam member 374 changes the angle of the cam surface 390. The cam surface 390 can include an optional dwell point 394 (shown in phantom in FIG. 9), which will be described below.

[0069] The cam members 374 cooperate with another portion of the bag manipulating assembly 70. As best seen in FIGS. 8 and 9, a support beam 398 is fixedly supported between the guide rails 314. Unlike the upper and lower jaw support members 310, 322, the support beam 398 is not free to move vertically along the guide rails 314. A pair of gripper arm assemblies 402 (see FIG. 9) are mounted on the support beam 398 in spaced-apart, opposing relation. The gripper arm assemblies 402 are substantially identical, and only one will be described in detail.

[0070] Each gripper arm assembly 402 includes a bracket member 406 having a base portion 410 and an arm portion 414. A gripper arm 418 is pivotally connected to the base portion 410 at pivot point 422. A cam follower 426 is mounted to the gripper arm 418 and engages the cam surface 390. In the illustrated embodiment, the cam follower 426 is a roller. A linear actuator or gripper 430 is mounted on the end of the gripper arm 418 for gripping the side edges of a bag 150, as will be described below. The gripper 430 is preferably a pneumatically-actuated, parallel gripper.

[0071] With continuing reference to FIG. 9, as the upper jaw support member 310 moves downwardly, the cam followers 426 roll on the cam surfaces 390 and the gripper arms 418 pivot about the pivot points 422 in a plane substantially normal to the longitudinal axis 94. Downward movement of the upper jaw support member 310 causes the gripper arms 418 and the grippers 430, to move away from one another. As the upper jaw support member 310 moves upwardly, the gripper arms 418 and the grippers 430 move back toward each other in a plane substantially normal to the longitudinal axis 94. The dwell points 394 in the cam surfaces 390 are designed to change the cam surfaces 390 so that the pivot arms 418 will not pivot during certain points of the operation of the bag filling station 50, as will be described below.

[0072] On both gripper arm assemblies 402, a linear actuator 434 is connected between the arm portion 414 and the gripper arm 418. Together, the linear actuators 434 are operable to pivot the gripper arms 418 even further away from one another than would otherwise occur via the normal movement of the cam followers 426 along the cam surfaces 390. The linear actuators 434 are preferably short-stroke pneumatic actuators. As will be described below, the linear actuators 434 are preferably actuated just prior to the sealing of the bag 150 when the upper jaw support member 310 is at its lowermost vertical limit.

[0073]FIG. 11 illustrates a pair of alternative gripper assemblies 438 that can be used in place of the gripper arm assemblies 402. Instead of the cam action used to pivot the gripper arm assemblies 402, the alternative gripper assemblies 438 are fixedly mounted to the opposing vertical members of the frame support section 286, and are linearly actuated to move the grippers 430 toward or away from each other. The gripper assemblies 438 are substantially identical and include back-to-back cylinders 442, 443 having respective rods 446, 447.

[0074] The rod 446 is connected to a sliding portion 450, which slides on a guide rail 454. Actuation of the cylinder 442 moves the rod 446 and causes movement of the sliding portion 450. The rod 447 is connected to a body portion 456 that is fixed with respect to the frame support section 286. Actuation of the cylinder 443 causes the cylinders 442 and 443 to move with respect to the body portion 456, thereby causing movement of the sliding portion 450. The gripper 430 is mounted on the sliding portion 450 so that actuation of either of the cylinders 442, 443 causes the grippers 430 to move toward or away from one another.

[0075] The components of the bag manipulating assembly 70 operate to receive the bag 150 from the bag loading assembly 66, open the open end of a bag 150 so that the package 102 can be inserted, and close the open end of the bag 150 once the package 102 has been inserted. The bag 150 is closed in a manner that is conducive to obtaining a quality seal of the open end of the bag 150. The bag 150 is under the control of the bag manipulating assembly 70 from the time it is received to the time it is removed from the loading station 58.

[0076] The bag welding assembly 74 is used to weld or seal the open end of the bag 150 after the package 102 has been inserted. The welding assembly 74 includes the upper and lower welding jaws 350, 326 and the associated hardware, which are available from TOSS Machine Components Inc. of Nazareth, Pa. As seen in FIG. 13, in one embodiment, each of the welding jaws 326, 350 includes a body portion 458, a fiberglass strip 462, a silicon strip 466, a teflon strip 470, and a weld wire 474. A layer of teflon tape 478 surrounds the working ends of the welding jaws 326, 350. Of course, welding could be accomplished with only one of the welding jaws 326, 350 having a weld wire 474.

[0077] The upper welding jaw 350 can also include a cutter assembly 482 that trims off a portion of the bag 150 after the open end has been sealed. The cutter assembly 482 can include a knife edge 486 that extends to trim the bag 150 when the welding jaws 326, 350 are closed. Of course, other cutter assembly configurations can be used. For example, a welding jaw having a sealing wire that simultaneously seals and cuts the bag 150 could also be used.

[0078] The welding assembly 74 also includes the pressure measurement devices 324 mounted on the lower struts 318. The pressure measurement devices are used to measure the pressure between the welding jaws 326, 350 while the bag 150 is sealed. Recall that as the lower welding jaw 326 reaches its uppermost vertical limit (i.e., the position where the welding takes place), the lower struts 318 are substantially vertical. This orientation promotes accurate measuring of the welding pressure because the pressure measurement devices 324 are in axial alignment with the forces exerted on the lower welding jaw 326 by the upper welding jaw 350.

[0079]FIG. 12 illustrates an alternative arrangement for the pressure measuring device. In FIG. 12, a pressure measurement device 490 (i.e., a load cell or the like) is mounted in a recess in the upper welding jaw 350. A contact disk 494 is mounted in a recess in the lower welding jaw 326. Multiple sets of devices 490 and disks 494 can be spaced along the length of the welding jaws 326, 350 as desired.

[0080] Regardless of the pressure measuring arrangement used, the pressure measuring devices 324, 490 are used to monitor the quality of the seal that is created by the welding jaws 326, 350, as will be described below. Verifying the formation of a quality seal without human intervention, and being able to document and record the process for future reference is an advantage of the bag filling station 50. The bags 150 are sealed using heat to melt the open end of the bag 150 together, as is understood. At least three components are important to achieve a good seal: pressure, temperature, and time. The bag filling station 50 monitors these three components so that the quality of the seal can be validated, which is especially important when packaging medical devices.

[0081] Time is the easiest to control, and refers to the time the pressure and heat are applied during the sealing process. Temperature is more difficult to control and measure, but suitable products are available. Pressure is applied using the drive device 302, such as an electric motor. Controlling the pressure entails controlling the current in the electric motor. Alternatively, pressure could be controlled via an air-cylinder (not shown). Pressure is measured using the pressure measurement devices 324, as described below.

[0082] During the sealing process, the weld wires 474 are heated to a temperature set by a controller or processor 502. The processor 502 is preferably a programmable logic control device and can have a video display 506. The temperature is held for a predetermined time dictated by the processor 502. The actual temperature of the weld wires 474 is monitored and temperature signals are sent to the processor 502 via signal lines 510. The actual temperature is compared to predetermined temperature settings.

[0083] When the heat command is removed, the welding seam is allowed to cool and pressure is applied for a time specified by the processor 502. As seen in FIG. 8, the pressure measuring devices 324 are linked to the processor 502 via lines 512. The processor 502 analyzes the signals from the pressure measurement devices 324 and determines the actual welding pressure applied. In one embodiment, the measured pressure, heat, and time values are displayed on the video display 506 and are compared to predetermined values to determine the quality of the seal. Additionally, two or more pressure measurements (corresponding to the number of pressure measurement devices 324 or 490 used) are compared to one another to determine the consistency of the seal along the length of the welding jaws 326, 350. With this approach, inconsistent or incomplete sealing caused by debris between the welding jaws 326, 350 or wrinkles in the bag 150 can be detected.

[0084] The processor 502 reads and records the pressure and temperature data at a predetermined sampling rate that allows the process to be validated. Each seal has data associated with it that the seal was heated to a certain temperature and that a certain pressure was maintained for a certain time. If any of the data indicates that improper sealing conditions were present, the sealed bag is rejected. While not shown, the bag filling station 50 can also include a marking device that can be used to catalog the sealed bags by placing some form of indicating feature (i.e., a serial number, a bar code, or the like) on the bags that is linked to the weld data. When the bags are marked with an indicating feature, the seal quality of any bag can be verified at a later time.

[0085] The operation of the bag filling station 50 will now be described. The bags 150 are first stacked in the bag tray 262 so that the open ends are to the right as viewed in FIG. 3. The bag tray 262 is then slid into place underneath the conveyor table 160. With the conveyor table 160 in the substantially horizontal first position P_(H), the lifting mechanism 278 is actuated to lift the stack of bags 150 toward the bottom surface 210 of the body portion 162. As seen in FIG. 4, when vacuum is applied to the lower cavity 186, the top bag 150 on the stack of bags is engaged by the conveyor belt 178 due to the vacuum communication between the apertures 214 and the transverse apertures 246. Once the top bag 150 is engaged with the conveyor belt 178, the lifting mechanism 278 is lowered to lower the stack of bags 150 away from the bottom surface 210.

[0086] Next, the drive device 234 indexes the drive roller 166 such that the bag 150 moves with the conveyor belt 178 as shown in FIG. 5. Vacuum is applied to the follower roller 170 to hold the bag 150 in engagement with the conveyor belt 178 as the bag 150 passes over the follower roller 170. At approximately the same time, the drive device 250 drives the linkage members 254 to move the conveyor table 160 from the first position P_(H) to the second, inclined position P_(I). As the bag 150 approaches the top surface 202, vacuum is applied to the upper cavity 182 to maintain the engagement between the conveyor belt 178 and the bag 150. At about the same time, the vacuum is turned off in the lower cavity 186. Once the conveyor belt 178 has traveled a predetermined distance (as gauged by the programmable motor or the sensing device), and the bag 150 is on top of the conveyor table 160, the drive device 234 reverses direction to load the open end of the bag 150 into the loading station 58 as shown in FIG. 6.

[0087] FIGS. 13-20 and 21-28 illustrate (from the side and the front, respectively) the sequential operation of the bag manipulating assembly 70 and the bag welding assembly 74 once the bag 150 is loaded into the loading station 58. As seen in FIGS. 13 and 21, the bag is moved into the loading station 58 and the side edges of the bag 150 pass through the open grippers 430. The open end of the bag 150 is oriented substantially horizontally in the loading station 58 as shown. The upper and lower welding jaws 350, 326 (and therefore the upper and lower bag spreader assemblies 348, 352) are slightly opened to provide clearance for the bag 150. In this position, the cam followers 426 are positioned in or near the dwell point 394.

[0088] Next, as seen in FIGS. 14 and 22, the grippers 430 close, thereby securely clamping the opposing side edges of the bag 150 to maintain control over the bag 150 at all times during the packaging operation. Additionally, the welding jaws 326, 350 close so that the suction cups 334, 358 approach the open end of the bag 150 from both sides. Due to the presence of the dwell points 394, the grippers 430 do not move toward each other as the jaws 326, 350 close. Vacuum is applied to the suction cups 334, 358 so that the suction cups 334, 358 engage both sides of the open end of the bag 150.

[0089] As seen in FIGS. 15 and 23, the welding jaws 326, 350 then open slightly. Because the suction cups 334, 358 have a suction grip on the top and bottom of the open end of the bag 150, the bag 150 opens slightly in response to the opening of the welding jaws 326, 350. Again, due to the dwell point 394, the grippers 430 do not move toward each other. The grippers 430 (shown schematically in FIG. 15) remain closed to keep a secure grip on the side edges of the bag 150.

[0090] Next, as seen in FIGS. 16 and 24, the rotary actuators 338, 362 are actuated so that the spreader plates 346, 370 rotate into the open end of the bag 150. The pins 342, 366 of the rotary actuators 338, 362 also retract to draw the spreader plates 346, 370 closer to the respective suction cups 334, 358. Meanwhile, the suction is still being applied to the bag 150 by the suction cups 334, 358. The grippers 430 remain closed.

[0091] At this point, it is worth noting that other spreader plate arrangements can also be used to open the bag. FIGS. 30-32 illustrate alternative upper and lower bag spreader assemblies 514 and 518, respectively. Instead of the rotary actuators 338, 362 having the rotating and translating spreader plates 346, 370, the alternative upper and lower bag spreader assemblies 514 and 518 include respective upper and lower pivoting bag spreader plates 522 and 526. Respective actuators 530 and 534 cause the pivoting bag spreader plates 522 and 526 to pivot into and out of the open end of the bag 150 as is sequentially shown in FIGS. 31 and 32.

[0092] Returning to FIGS. 17 and 25, the welding jaws 326, 350 are opened wider so that the open end of the bag 150 is opened widely enough to receive a package 102. Both the suction cups 334, 358 and the spreader plates 346, 370 aid in opening the bag 150. As best seen in FIG. 9, when the upper welding jaw 350 is moved upwardly to open the bag 150, the gripper arms 418 pivot inwardly toward each other in response to movement of the cam members 374. The inward pivoting of the gripper arms 418 moves the grippers 430 toward each other and facilitates spreading the open end of the bag 150 apart. The grippers 430 remain closed to hold the side edges of the bag 150.

[0093] Sometime before the package 102 is pushed into the bag 150, the conveyor table 160 of the bag loading assembly 66 is returned to the first, substantially horizontal position P_(H) (see FIGS. 1 and 4) so that the package 102 can be pushed into the bag 150 without being obstructed by the follower roller 170. Returning the conveyor table 160 to the horizontal position also prepares the bag loading assembly 66 for picking up the next bag 150 from the stack.

[0094] At this point, the bag 150 is ready to receive a package 102. The package 102 is placed on the conveyor table 106 (see FIG. 1) and the drive device 118 drives the conveyor belt 114 to move the package 102 toward the loading station 58. The pusher arms 134 are in the retracted position P_(R) (see FIG. 1a) to allow the package 102 to pass by. When the sensor 142 detects the package 102, the conveyor belt 114 stops and the pusher arms 134 move to the extended position P_(E) to overlie the conveyor table 106. The pusher arm assemblies 122 then move linearly toward the waiting package 102 so that the pushing ends 138 engage the package 102 (see FIGS. 1b and 10) and push the package 102 into the bag 150 (see FIGS. 18 and 26). The pusher arms 134 are then withdrawn from the bag 150 and returned to the retracted position P_(R) in anticipation of the next packaging cycle.

[0095] With the package 102 inside the bag 150, the bag 150 is sealed. As seen in FIGS. 19 and 27, the welding jaws 326, 350 close so that the open end of the bag 150 closes. Just prior to closing, the spreader plates 346, 370 rotate out of the bag 150. The suction is turned off at the suction cups 334, 358. As the upper welding jaw 350 moves downwardly, the gripper arms 418 pivot outwardly, away from each other. Since the grippers 430 are still closed on the side edges of the bag 150, the outward movement of the gripper arms 418 acts to stretch the bag 150, thereby helping to flatten the open end of the bag 150 in preparation for sealing.

[0096] To ensure that the open end of the bag 150 closes substantially without any wrinkling caused by the bulky package 150 inside the bag, the linear actuators 434 connected to the gripper arms 418 (see FIGS. 8 and 9) pull the gripper arms 418 even further outwardly, away from each other. This additional outward movement of the grippers 430 stretches the side edges of the bag 150 apart even further to completely flatten the open end of the bag 150 and to substantially remove any wrinkles that could cause inconsistent or incomplete sealing.

[0097] Electricity is applied to the weld wires 474 to heat seal the open end of the bag 150, as is understood. The processor 502 monitors the weld temperature, pressure, and time as described above to monitor the quality of the seal obtained.

[0098] Either during, or just after welding, the cutter assembly 482 is activated to trim the bag 150 as shown in FIG. 20. As shown in FIG. 28, the trimmed bag pieces 538 are removed from the loading station 58 using a vacuum tube 542. The vacuum tube 542 is a tube positioned adjacent the loading station 58 where the trimmed bag pieces 538 are located. Vacuum supplied to the vacuum tube 542 extracts the trimmed bag pieces 538 and deposits them in a waste receptacle (not shown). Of course, other methods of removing the trimmed bag pieces 538 can be used. Alternatively, the sealed bag 150 need not be trimmed at all.

[0099] With the bag 150 packed and sealed, the grippers 430 are opened to release the side edges of the bag 150 and the conveyor belt 178 is activated to move the sealed bag 150 out of the loading station 58 and to the take-off conveyor 282 (see FIGS. 7 and 8). As seen in FIGS. 7 and 8, the next packaging cycle is underway and the next bag 150 from the stack is concurrently being engaged and moved into the loading position by the conveyor belt 178.

[0100] While not shown in the figures, the follower roller 170 can also be adapted to remove the air from inside the packed and sealed bag 150 if vacuum packing is desired. Alternatively, vacuum packing could occur at a later time on a different machine.

[0101]FIG. 29 illustrates a packed and sealed bag 150. The sealed area extends across the width of the bag 150 and is generally designated by the reference numeral 546.

[0102] An alternate embodiment of the bag filling station 50 is illustrated in FIGS. 33-43. Many of the components in the alternate embodiment are similar to the components in the preferred embodiment, therefore like components will be given like reference numbers. In this embodiment, the bag filling station 50 can load, fill, and seal bags 150 with packages 102 of varying size. Unlike the embodiment described above where the bag 150 is trimmed after the bag 150 has been sealed, in the alternate embodiment the bag 150 is trimmed to a desired size before the package 102 is loaded into the bag 150.

[0103] The bag loading assembly 66 (See FIG. 1) remains the same, except that the drive roller 166 can be selectively manipulated to feed varying amounts of the bag 150 into the loading station 58 at varying distances. The loading assembly 66 can feed less of the bag 150 for larger packages 102 or the loading assembly 66 can feed more of the bag 150 for smaller packages 102.

[0104] An alternate bag spreading assembly 600 is shown in FIGS. 33-34. The bag spreading assembly 600 includes upper and lower jaw support members 310 and 322 that support upper and lower welding jaws 350 and 326, respectively, suction cups 334 and 358, a cutter assembly 482 having a knife edge 486, upper and lower bag gripper assemblies 604 and 608, and upper and lower drive members 612 and 616.

[0105] The suction cups 334 and 358 are located on the bag loading assembly 60 side of the upper and lower welding jaws 350 and 326. The cutter assembly 482 is mounted on the upper welding jaw 350 and the knife edge 486 is slidably mounted to the cutter assembly 482, such that the knife edge 486 can slide vertically downward to cut the bag 150 and slide vertically upward to a starting position where the knife edge 486 does not contact the bag 150.

[0106] The upper gripper assembly 604 includes a retainer 636, a connecting arm 640, a gripper arm 644, a gripper bracket 648, and an upper gripper plate 652. The upper gripper assembly 604 is connected to the upper drive member 612 by a drive arm 628 and a square axle 632. The drive arm 628 is mounted to the drive member 612 at one end of the drive arm 628 and to the square axle 632 at the other end of the drive arm 628. The square axle 632 extends through and turns the retainer 636, therefore causing the upper gripper assembly 604 to move when the square axle 632 is rotated by the drive member 612.

[0107] The connecting arm 640 is pivotally connected to the retainer 636 at one end and is pivotally connected to the gripper arm 644 at a second end. The other end of the gripper arm 644 is mounted to the gripper bracket 648. The gripper bracket 648 is mounted to the upper gripper plate 652. The gripper bracket 648 includes a follower 656 that slidably mounts the gripper bracket 648 to a guide member 660. The follower 656 inserts into a slot 664 in the guide member 660, such that the upper gripper plate 652 follows a desired path determined by the follower 656 traveling through the slot 664 (discussed in greater detail below).

[0108] The lower gripper assembly 608 includes a retainer 668, a connecting arm 672, a gripper arm 676, a gripper bracket 680, a lower gripper plate 684, a transfer plate arm 688, and a transfer plate 692. The lower gripper assembly 608 is connected to the lower drive member 616 by a drive arm 696 and a square axle 700. The drive arm 696 has one end mounted to the drive member 616 and the other end mounted to the square axle 700. The square axle 700 extends through and turns the retainer 668, causing the lower gripper assembly 608 to move when the square axle 700 is rotated by the drive member 616.

[0109] The connecting arm 672 has one end pivotally connected to the retainer 668 and a second end pivotally connected to the gripper arm 676. The other end of the gripper arm 676 is mounted to the gripper bracket 680. The gripper bracket 680 is mounted to the lower gripper plate 684. The gripper bracket 680 includes a follower 704 that slidably mounts the gripper bracket 680 to a guide member 708. The follower 704 inserts into a slot 712 in the guide member 708, such that the lower gripper plate 684 follows a desired path determined by the follower 704 traveling through the slot 712 (discussed in greater detail below).

[0110] The transfer plate arm 688 is pivotally connected at one end to the pivotal connection between the connecting arm 672 and the gripper arm 676 and pivotally connected at a second end to a transfer bracket 716, which is mounted to the transfer plate 692. The transfer plate 692 is positioned on top of the lower gripper plate 684 and allows the package 102 (see FIG. 1) to be pushed over the gripper plate 684 without snagging. The transfer plate 692 travels in a circular path and rotates about a pin 720 in such a way that interference between the transfer plate 692 and the lower gripper plate 692 (discussed in greater detail below) is minimized.

[0111] The upper and lower gripper assemblies 604 and 608 have the capability of adjusting laterally along the upper and lower jaw support members 310 and 322. The upper and lower gripper assemblies 604 and 608 can adjust laterally to accommodate bags 150 and packages 102 of varying widths, therefore giving the bag filling station 50 a broader range of applications and possibly eliminating machines that only fill bags 150 of one size. To ensure proper alignment an upper scale 722 and a lower scale 723 are mounted to the upper and lower jaw support members 310 and 322, respectively. The upper and lower gripper assemblies 604, 608 can be positioned along the upper and lower scale 722 and 723, respectively.

[0112] The upper and lower gripper plates 652 and 684 include an upper rubber plate 724 and a lower rubber plate 728, respectively, that press the edges of the bag 150 against the upper and lower welding jaws 350 and 326, respectively. The rubber plates 724, 728 resiliently hold the edges of the bag 150 in place as the bag 150 is opened and the package 102 is loaded into the bag 150.

[0113] The process of loading and sealing the package 102 with the bag spreading assembly 600 will now be described. Referring to FIG. 35, the bag 150 is loaded into the bag spreading assembly 600. As stated above, the drive roller 166 (see FIG. 3) feeds the desired amount of bag 150 into the bag spreading assembly 600 and the bag 150 is grasped by the grippers 430. The upper and lower bag gripper assemblies 604, 608 are positioned in a start position, where the upper and lower 5 gripper plates 652 and 684 and transfer plate 692 are generally horizontal and parallel to the longitudinal axis 94.

[0114] Referring to FIG. 36, the upper and lower welding jaws 350 and 326 come together after the grippers 430 have grasped the bag 150. At this time any excess portion of the bag (referred to as a tail 624) is cut away by the extending knife edge 486. The suction cups 334 and 358 contact both sides of the open end of the bag 150 and vacuum is applied to the suction cups 334 and 358.

[0115] Referring to FIG. 37, the upper and lower welding jaws 350 and 326 open slightly. Because the suction cups 334, 358 have a suction grip on the top and bottom of the open end of the bag 150, the bag 150 opens slightly in response to the opening of the upper and lower welding jaws 350 and 326. The tail 624 is grasped by tail removing conveyers 620 and is removed from the bag spreading assembly 600 in a direction generally orthogonal to the longitudinal axis 94 (see FIG. 1). The grippers 430 maintain a grip on the bag 150, but as the bag 150 is opened, the grippers 430 move together to adjust for the decrease in width and the increase in height of the bag 150 (similar to the embodiment shown in FIGS. 21-26).

[0116] Referring to FIG. 38, the upper and lower bag gripper assemblies 604 and 608 begin moving. The upper and lower bag gripper assemblies 604 and 608 allow the bag 150 to be opened further than with the suction cups 334 and 358 alone. The gripper assemblies 604 and 608 are driven by the drive members 612 and 616, respectively. The transfer plate 692 rises first and remains above the lower gripper plate 684. The lower gripper plate 684 begins to rise slightly and is angled toward the opening between the separated sides of the bag 150. The upper gripper plate 652 begins to lower and is also angled toward the opening between the separated sides of the bag 150.

[0117] Referring to FIGS. 39 and 40, the upper and lower drive members 612 and 616 continue to drive the upper and lower bag gripper assemblies 604 and 608, respectively, and the suction cups 334, 358 continue to separate and further open the bag 150. The transfer plate 692 continues to rise above the lower gripper plate 684. The lower gripper plate 684 also continues to rise and begins to move laterally toward and into the opening between the separated sides of the bag 150. The upper gripper plate 652 continues to lower and also begins to move laterally toward and into the opening between the separated sides of the bag 150.

[0118] Referring to FIG. 41, the upper and lower bag gripper assemblies 604 and 608 have reached peak positions. The upper and lower gripper plates 652, 684 are inserted as far into the opening between the separated sides of the bag 150 as the upper and lower gripper plates 652 and 684 will go. The upper and lower gripper plates 652 and 684 are also brought into contact with the edges of the bag 150 through the rubber plates 724, 728 so that the bag 150 can be opened further than with the suction cups 334, 358 alone. At this ultimate position, the package 102 is pushed into the bag 150 by the pusher arm 134. The package 102 slides smoothly over the transfer plate 692, which covers the lower gripper plate 684.

[0119] Referring to FIG. 42, the package 102 is fully inserted into the bag 150, the upper and lower bag gripper assemblies 604 and 608 have returned to the start position (as seen in FIG. 35), and the upper and lower jaw support members 310 and 322 (see FIG. 33) are brought together. As the upper and lower jaw support members 310 and 322 are brought together, the edges of the bag 150 are brought together between the upper and lower welding jaws 350 and 326. The upper and lower welding jaws 350 and 326 weld the edges of the bag 150 together and form an air tight seal 546 (see FIG. 29).

[0120] Referring to FIG. 43, the motion of the transfer plate 692 and the lower gripper plate 684 are illustrated. The transfer plate 692 rotates about the pin 720 in a circular path and is driven by the movement of the lower drive member 616. The transfer plate 692 raises and lowers such that the transfer plate 692 does not interfere with the motion of the lower gripper plate 684. The motion of the lower gripper plate 684 (as seen in phantom in several positions) is more complicated than the motion of the transfer plate 692. The lower gripper plate 684 first moves upward and slightly rearward away from a hold down plate 732 to ensure that the lower gripper plate 684 does not interfere with the hold down plate 732. The lower gripper plate 684 continues to move upward and begins to move forward toward the lower welding jaw 326. The lower gripper plate 684 continues to move forward, but reaches a vertical peak position and begins to move downward toward the lower welding jaw 326. The lower gripper plate 684 continues to move forward and downward until the rubber plate 728 on the lower gripper plate 684 contacts the lower welding jaw 326. The lower gripper plate 684 and transfer plate 692 return to the start position (shown in solid lines) in a reverse direction along the same path described above.

[0121] As discussed above, the alternate embodiment of the bag filling station 50 can load, fill, and seal bags 150 with packages 102 of varying size. The bag 150 is loaded into the loading station 58 at a plurality of distances by the drive roller 166. The bag 150 is cut to size by the cutter assembly 482 and the tail 624 is removed from the bag spreading assembly 600 by the tail remover conveyors 620. The bag 150 is opened by the bag spreading assembly 600, which includes the upper and lower gripper assemblies 604 and 608. The package 102 is loaded into the bag 150 and the upper and lower welding jaws 350 and 326 seal the bag 150.

[0122] The embodiments described above and illustrated in the figures are presented by way of example only and not intended as a limitation upon the concepts and principles of the present invention. As such, it will be appreciated by one having ordinary skill in the art that various changes in the elements and their configuration and arrangement are possible without departing from the spirit and scope of the present invention.

[0123] Various features of the invention are set forth in the following claims. 

1. A device for filling and sealing bags, the device comprising: a frame; a loading station within the frame; and a bag loading assembly coupled to the frame and adjacent the loading station, the bag loading assembly including a bag holder for holding a stack of bags; and a conveyor assembly adjacent the bag holder and movable between a first position, where the conveyor assembly engages a bag from the stack of bags, and one of a plurality of second positions, where the conveyor assembly loads an open end of the bag into the loading station at one of a plurality of distances.
 2. The device of claim 1, wherein the conveyor assembly is substantially horizontal when in the first position and is inclined when in the second position.
 3. The device of claim 2, wherein the conveyor assembly is pivotable between the first and one of the plurality of second positions.
 4. The device of claim 1, further including a lifting device coupled to the bag holder for moving the stack of bags with respect to the conveyor assembly.
 5. The device of claim 1, wherein the conveyor assembly includes first and second rollers, a body portion between the first and second rollers, an endless belt encircling portions of the rollers and the body portion, and at least one vacuum generator communicating with the body portion for providing vacuum to the conveyor assembly.
 6. The device of claim 5, wherein at least one of the rollers is driven by a drive device and selectively operable to selectively determine the distance the bag is fed into the loading station.
 7. The device of claim 6, wherein the drive device is a motor.
 8. The device of claim 5, wherein the body portion includes an upper cavity communicating with an upper surface of the conveyor assembly and a lower cavity communicating with a lower surface of the conveyor assembly.
 9. The device of claim 8, wherein a first vacuum supply communicates with the upper cavity and a second vacuum supply communicates with the lower cavity to independently apply vacuum to the upper surface of the conveyor assembly and to the lower surface of the conveyor assembly.
 10. The device of claim 5, wherein at least one of the rollers communicates with a vacuum generator to supply a vacuum to an outer surface of the roller.
 11. The device of claim 5, wherein the endless belt includes apertures for communicating vacuum through the endless belt to a bag.
 12. The device of claim 5, wherein the body portion has an overall width and a working width over which a vacuum communicates with the endless belt, the working width being adjustable to handle bags of varying sizes.
 13. A device for filling and sealing bags, the device comprising: a frame; a loading station within the frame; a package loading assembly coupled to the frame and adjacent the loading station; a bag loading assembly coupled to the frame and adjacent the loading station, the bag loading assembly including a bag holder for holding a stack of bags; a conveyor assembly adjacent the bag holder and movable between a first position, where the conveyor assembly engages a bag from the stack of bags, and one of a plurality of second positions, where the conveyor assembly loads an open end of the bag into the loading station at one of a plurality of distances; and a bag manipulating assembly coupled to the frame to facilitate gripping the bag and opening the bag, the bag manipulating assembly including a plurality of gripper plates for gripping the bag and opening the bag, the gripper plates extending longitudinally into the bag.
 14. The device of claim 13, further comprising a welding assembly coupled to the frame for sealing the open end after the package has been loaded into the bag.
 15. The device of claim 13, further comprising a cutter assembly for cutting a tail from the bag, the cutter assembly including a knife extendable through the bag to separate the tail from the bag.
 16. The device of claim 15, further comprising a tail removing conveyor for removing the tail from the device.
 17. A method of packaging an item in a bag using an automated packaging device, the method comprising: providing a loading assembly feeding a selective amount of an open end of a bag into a loading station; cutting a tail of the bag from the bag; removing the tail from the automated packaging device; and providing a bag manipulating assembly having a plurality of gripper plates for gripping the bag and opening the bag, the gripper plates extending longitudinally into the bag. loading the item into the bag;
 18. The method of claim 17, wherein the loading assembly feeds the bag into the loading station at one of a plurality of distances.
 19. The method of claim 17, further includes loading the item into the bag after the bag has been opened.
 20. The method of claim 19, further includes providing a welding assembly having an upper welding jaw and a lower welding jaw, at least one of the upper and the lower welding jaws being movably coupled to the frame via at least one support member.
 21. The method of claim 20, further includes sealing the open end of the bag between the welding jaws after the item has been loaded into the bag.
 22. A device for opening and sealing a bag, the device comprising: a frame; a loading station within the frame; a bag loading assembly coupled to the frame and adjacent the loading station, the bag loading assembly including a bag holder for holding a stack of bags; and a conveyor assembly adjacent the bag holder and movable between a first position, where the conveyor assembly engages a bag from the stack of bags, and one of a plurality of second positions, where the conveyor assembly loads an open end of the bag into the loading station at one of a plurality of distances; an upper jaw movable in a substantially vertical plane; a lower jaw movable in the same substantially vertical plane as the upper jaw and supported on the frame by at least one support member; an upper gripper plate pivotally mounted to the upper jaw, the upper gripper plate being operable to extend longitudinally into the bag and open the bag; and a lower gripper plate pivotally mounted to the lower jaw, the lower gripper plate being operable to extend longitudinally into the bag and open the bag.
 23. The device of claim 22, wherein the upper and lower gripper plates extend longitudinally into the bag at substantially the same time.
 24. The device of claim 22, firther comprising an upper welding jaw coupled to the upper jaw and a lower welding jaw coupled to the lower jaw, wherein the upper welding jaw and the lower welding jaw operate in unison to seal an open end of the bag. 